Apparatus and method for making cushions



- Jan. 3, 1950 J. w. BOWERSOX APPARATUS AND METHOD FOR MAKING CUSHIONS Filed Sept. 14, 1944 s Sheefs-Sheet 1 Jan, 3, 1950 .1. w. BOWERSOX 2,493,652

APPARATUS AND METHOD FOR MAKING CUSHIONS Filed Sept. 14,. 1944 3 Sheets- Sheet 2 Jan. 3, 1950 w, BOWERSOX- 2,493,652

APPARATUS AND METHOD FOR MAKING CUSHIONS Filed Sept. 14, 1944 3 Sheets-Sheet 3 Patented Jan. 3, 195% APPARATUS. AND.- METHOD: FOR- MAKING CUSHION-S Joseph W. Bower-sax, St. Petersburg, Fla, assi'g-nor to. Sealy, Incorporate'd',.Memphis, Tenm, acorporati'onof Delaware- Applications'eptember 14, 1944, Serial No. 554,114

10 Claims.v 1.

This invention relates in general to cushion making and is more particularly described as an improved method and apparatus for making mattresses from cotton fiber.

An important object of the invention is to provide a method and apparatus for-more accurately varying and controlling the distribution of a filling material such as cotton fiber or lint in producing a mattress.

A further object of the invention is to improve the method of compressing, handling and stufiing a mattress in a casing;

A further object of the invention is to provide an improved apparatus for receiving, compressing, handling, and facilitating the removal of a fibrous filler for mattresses and cushions.

Other objects of the invention will appear in the specification and will be' apparent from the accompanying drawings in which,

Fig. 1 is a sectional elevation of an apparatus for making cushions in accordance with this invention, showing deflectors at the bottom in one position; Fig. 2 is a partial sectional view of the bottom showing the deflectors in lowered position; Fig; 3isa viewof'the portion shown in Fig. 2 showing the filler in compressed condition; Fig; 4" is a cross-section illustrating a compressed mattress-filler readyto be inserted in a mattress cover; Fig. 5' isa sectional view illustrating the application of a mattress cover; Fig. fi-ill'ustrates one end of a mattress before the ends are'closed; Fig. 7 showsthe method of' compressing a number of filled mattresses in a pile; and Fig. 8 shows one end of a mattress with roll edges with rounded extensions at top and bottom.

In making cushions, and more particularly mattresses, from a fibrous filler such as cotton lint, ithas been the practice to distribute the lint at the bottom of a high container and then to compress and fill' a mattress cover with thematerial.

This method may be satisfactory for making a cushion of even thickness, but it is difficult to vary the distribution of the fibrous filling to produce a mattress in which one portion has a greater amount of filling than other portions, or to varythe distribution as desired in producing a particular result.

For example, it is found that a mattress tends to compress more at the center than at the ends due to the weights appliedthereto, and: it is therefore desirable thatthe mattress itself shall have a more resilient" andmore fibrous material at the center than atthe ends.

The present invention provides a simple and easily controlled means for varying the thickness or the amount of fibrous material at the ends, building up the fillingmaterial as desired in the center and transversely of the mattress, and at the same time insuring that all mattresses of the same size will have substantially the same amount of fiber distributed in the same places so that the variation will be exactly'thesame in all mattresses or cushions, thereby using mattress covers-of the same size and construction.

Referring now more particularly to the drawings, a rectangular upright container having a cross sectional area about thesize of amattress to be-formedis disposed in upright position upon a suitable base or support lll'toraise it to a convenient Working height. One end I! of the container is closed and continuous throughout its length. Two-oppositesidesr2 are continuous at the top and'eaeh has a lower'side wall 13 mountedon hinges M to swing upwardly, and the other end wall. has a lower door I5 mounted upon hinges l6 to swing upwardly from the bottom;

The hinged wall sections I-3 and l5 have movable latches l1 at their lower edges for engaging the support ['0- and holding these doors in closed position when desired.

At the upper end of the container is a screentop is with hinges i9 at one end for raising it if desired. At the center is a smalldoor- 20 which may be opened from the top for inserting a lift-- ing rope or cable 21'.

At one end ofthe upper portion is a cotton gin- 22 with a hopper 23 at one side for insertingcotton, and rapidly rotating shredding member 2'4 which also acts as a blower for forcibly ejecting finely divided fibrous cotton or similar material through a horizontal slot 25' near the top of the container. Pivoted at one end 26 above the slot, is a curved guide plate 21 movable about its pivot to guide and direct the material from the gin as it falls in the container. In order to set the guide plate at different positions, a, handle 28 extends outwardly at one end of the pivot which is adapted to resiliently engage any one of a series of notches 2901 an upright projection It 30 for holding it releasably in any position in which it is set.

In the bottom 3| of the container, are transverse grooves 32 which extend below the lower edges or. the hinged doors I3, and in these slots, cross pieces 33 are inserted. Extending from the lower edges of the side doors l3 are slots 34 which register with the grooves 32 and are of a size to admit cross pieces 33 thereto. Each slot is closed by a door 35 mounted on hinges 36 and having a latch 3! opened from the outside.

Mounted in the end'wall and upon the hinged end door I are deflector plates, each plate comprising an upper section 38 having horizontal hinges 39 at a distance above the bottom of the container, and a lower section 4|] connected to the lower end of the section 38 by hinges 4|. The deflector plates are preferably proportioned so that the upper portion 38, will fold against the end Wall and the lower portion 40 will collapse or fold adjacent the bottom as shown more clearly in Fig.- 2.

An adjusting means for each deflector plate operable from the outside of the container comprises a curved bar 42 attached at its inner end to the underside of the deflector plate section 38. The bar extends through an opening 43 in each side wall and has notches 44 in its lower edge adapted to engage a plate 45 attached to the outside of the Wall or door and projecting into the opening 43 so that the notches 44 may be engaged with the edge of the plate.

To form a supporting base at the bottom of the container, two or more thin, wide boards 46 are laid endwise in the bottom and overlying cross pieces 33 therein with angular metal plates 41 at the sides.

To compress a mattress filling from its upper side, a rack 50 is inserted in the container, which comprises a rectangular frame having a central cross piece 5| raised at one side of the rack and having a' hole 52 centrally of the other side 'of the rack for the engageemnt of a hook 53 at the end of the hauling rope 2|. In the opposite edges of the rack are notches 53 for receiving cross pieces 54 corresponding to the lower cross pieces 33 and being of a length to extend beyond the side walls of the container through the slots 34 in the hinged doors l3 when the cross pieces are inserted.

Mattress filling and compressing strips 55 are mounted on the rack extending lengthwise thereof, engaging the projecting edge of cross piece 5| at the center, and the ends of the strips being engaged by grippers 56 pivoted at the ends of the rack and extending over the ends of the strips 55 for holding them in connection with the rack, the slight bowing of the strips over the central support 5| serving to hold them resiliently in engagement'with the grippers.

In operation, the bottom strips 46, 4! are in-' serted in place before the side and end doors are closed, and below the deflector plate of the fixed end H; the other end wall I5 is lowered and the deflector plate 38, 4B is raised or set in position as desired. The side walls I3 are closed and the gin 22 is set into operation. The fibrous material 60, such as cotton lint, is distributed evenly throughout the container and the desired amount of such material is fed into the gin which will fill the bottom of the container evenly to a certain height or level except that the space below the deflectors 38 is not filled with the material. By withdrawing the deflector plates 38, 4!] from both ends of the containerso that they are parallel to the side and bottom walls, the end portions of the fibrous material will thus sink or fall a corresponding amount so that the material at the top of the container then assumes a rounded condition with the material evenly distributed in felted relation, but the end portions considerably thinner than the rounded central portion so that there will be more fibrous material at the center of the mattress than at the ends.

This light fibrous material gradually sinks in the container until the upper level is just below the upper edge of the hinged walls l3 and I5 so that the rack may be inserted therein by first raising the end wall l5, by then lowering the rope 2| through the opened door 20 at the top, the hook 53 being drawn out through the opening of the door l5, and the hook engaged with the hole 52 in the cross piece 5| of the rack. The rack is then hauled into the container with the pressure strips at the underside thereof, the weight of the rack then causing the fibrous material to be compressed below the top of the side slots 34.

At this time, the slot doors 35 are opened and the upper cross ieces 54 are inserted above the upper pressure strips 55 and through the slots 53 of the rack. r

The rack may then be disengaged from the pressure strips 55 by first unhooking one end latch 56 which also releases the strips from the other end of the rack, since the strips are no longer bowed lengthwise, and the strips are held down by the upper cross pieces 54. The rack 50 is thereupon released and may be raised by the rope 3| and passed outwardly through the open end Wall I5.

I The fibrous mattress filling is thus compressed between the upper and lower pressure strips 55 and 46 and in order to compress the material still further, pressure is applied upon the upper cross pieces, pressing them downwardly below the side projections 52 at the edges of the slots 34 until they can be suitably engaged and held together by end clamps. The end clamps as shown comprise a U-shaped plate 64 of a width to receive the cross-pieces therein and of a length greater than the compressed distance between them so that a handle member 65 pivoted in the free ends of each member 64 may be rotated from an angular to an end position as shown in Fig. 4, further engaging and clamping the cross-pieces therebetween.

As thus compressed and held, the mattress filling is ready to be removed from the container, the side doors are raised upon their hinges by first disengaging the latches l1 and even though the lower deflector section 40, which is attached to the fixed wall may be engaged in the adjacent end of the filling, it can be released therefrom by pulling outwardly upon the compressed mattress filling, and the filling thus compressed is then carried away from the container and placed upon a table for receiving a mattress cover 10. In applying the mattress cover, one extremity of the filling which projects beyond the upper lower cross pieces will receive the cover sleeve or shell which is fitted or fluted thereon up to the cross pieces. These cross pieces may then be removed and the cover slipped further over the upper and lower compression strips until the next cross pieces are engaged, whereupon they, too, may be removed, and the cover applied over the entire length of the mattress. It is common practice to leave both ends of the mattress cover open; the upper and lower pressure strips and the angular corner pieces 41 may now be removed from one end,.the;flll1ng' stuifedipantially within the cushion cover, and a central portion 12 of each end of the cover may be. attached. to the opposite" side of" the cover. for transporting the filled mattress to a sewing machine.

After. the sewing operation is concluded; a number of. completed mattresses as 13 in Fig. '1 are placedunder a considerable weightfid as-shown in Fig. 7 to partially compress and shape. them, since the tendency of this mattress is to bulge more at the center than at the. ends because. of the greater amount of material which was purposely deposited in this location by means of the deflector plates.

After the mattresses have been compressed to shape under a weight for a predetermined time, upper and lower roll edges 16 may be applied thereto as shown in Fig. 8. This type of mattress needs no tufting; it has great resilience, and because of the excess material at the center, it does not become thin or compressed at this location even though this is the portion of the mattress which must bear the greatest weight. After some compression of this mattress, it regains resilience by subjecting it to fresh air and sunlight.

I claim:

1. The method of making mattresses which comprises the distribution of fibrous material at the top of a rectangular container so that it will fall into a mass at the bottom thereof, in placing deflectors at the bottom of the receptacle to guide the material as it falls by gravity, in filling the fibrous material level at the top in the container, in withdrawing the deflectors after the material is level at the top, and thereafter compressing the fibrous material and inserting it as thus disposed by the deflectors in a mattress cover.

2. The method of making a mattress which has a greater amount of fibrous material at one place than at another, which comprises spreading the fibrous material from the top of a rectangular closure in which it falls by gravity, in accumulating the fibrous material at the bottom of a container, in providing movable deflectors at the bottom of the container, in filling the fibrous material to a predetermined level in the container, in withdrawing the deflectors, in cornpressing the fibrous material with the deflectors withdrawn, and in applying the fibrous material to a mattress cover.

3. The method of making a mattress with more fibrous material at the center than at the ends, which comprises spreading fibrous material at the top of a closed rectangular container to settle by gravity at the bottom thereof, in applying deflectors at the ends of the receptacle for limiting the accumulation of fibrous material at the ends, in leveling the top of the fibrous material in the container, in withdrawing the deflectors at the ends, in compressing the fibrous material after the deflectors are withdrawn, and in filling a mattress cover with the fibrous material as thus distributed in the container.

4. The method of making mattresses having more fibrous material at the center than at the ends which comprises distributing fibrous material at the top of a rectangular container to fall by gravity therein, in diverting some of the material at the bottom of the container by deflectors at opposite ends thereof, in filling the material thus deflected to a predetermined level in the container, and in thereafter withdrawing the end deflectors and compressing the fibrous material, in removing the compressed fibrous materialfiatxthabottcmof the container, and: inserting;

it into" amattress cover, substantially or thesame area. as the bottom. of thecontainer.

5.. In a, mattress: making apparatus; a rectangularcontainer comprising a fiber shredding device for distributing fibrousmaterial at: the top of the container to=fall by gravity therein, means at: the top. of thecontainer for guiding the fibrous material therein, angularly disposed deflectors at thev bottom. of: the; end walls of the container, each deflector being hinged along its upper edge to one end wall of the container and hinged intermediateits upper and lower. edge to fold against the end and bottom. of. the. .0011? tainer, and means connected to the deflector and extendingthrough the end wall of the container for moving the deflector from its extended to its folded position.

6. In a mattress making apparatus, a rectangular upright container, means for applying and distributing fibrous material at the top of the container to fall by gravity therein, a deflector plate at each end of the bottom of the container, hinged along its upper edge to the end wall of the container and having a hinged joint intermediate its top and bottom to fold against the end wall to which it is hinged, and adjusting means connected to the deflector plate and extending through the wall to which it is hinged, having notches for engaging the Wall to said plate at different angles in the container.

7. In a mattress making apparatus, an upright rectangular container having fiber filling means at the top of the container, movable deflector plates attached to the walls at the bottom of the container, the lower portion of an end wall and the lower portions of the two side walls of the container being hinged to their respective walls, the bottom of the container having transverse grooves in which cross pieces are inserted, mattress filling strips at the bottom of the container overlying the cross pieces, a compression rack insertable through the end hinged Wall and applied above filling material at the bottom of the container, said rack comprising upper cushion stuffing strips, transverse cross pieces insertable above the upper cushion stufiing strips, and means engaging corresponding upper and lower cross pieces for binding them together against the pressure of fibrous mattress material compressed between them the top and bottom strips and connected cross pieces being removable with mattress material compressed between them through either one of the lower hinged side walls.

8. A structure, in accordance with claim 7, in which the opposite hinged side walls are provided with door closed slots extending upwardly from the lower edges opposite the lower cross pieces through which the upper cross pieces may be inserted for compressing fibrous material at the bottom of the container.

9. A mattress making apparatus, according to claim '7, in which the upper end of the container has a screened top with a central closed door, a rope insertable through the top of the door having a hook at its lower end, the hook being withdrawn from the side at the bottom of the container for engaging it with the rack for haul- ,ing the rack into the container and placing it on top of fibrous material settled by gravity therein.

10. A mattress making apparatus, according to claim '7, in which the hinged doors at opposite sides of the bottom of the container are provided with closed slots extending upwardly from 7 the bottom opposite the cross pieces in the bottom of the container to receive the upper cross pieces, and the sides of the slots having notche engageable by the upper cross pieces when they are pulled downwardly against fibrous material at the bottom of the container to retain the opposite ends of the upper cross pieces in compressing the fibrous material at the bottom of the container.

JOSEPH W. BOWERSOX.

REFERENCES CITED The following references are of record in the file of this patent:

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